Method and apparatus for making an absorbent composite
View Patent ↗A method and apparatus for making an absorbent composite from continuous tow is disclosed. The method and apparatus includes the steps of or means for spreading a crimped tow; de-registering the crimped tow; shaping the de-registered tow to a substantially rectangular cross-section; and distributing a particulate onto the shaped tow. The step of or means for de-registering the crimped tow uses at least two pairs of rollers, each pair of rollers having a metal-faced roller and a rubber-face roller. The metal-faced rollers are oppositely disposed between the pair of rollers. Alternatively, the metal-faced rollers are disposed between the pair of rollers on the same side.
1. A method for making an absorbent composite from a continuous tow comprising the steps of:
spreading a crimped tow;
de-registering the crimped tow by using at least two pairs of rollers, each pair of rollers having a metal-faced roller and a elastic-polymer-faced roller and the metal-faced rollers being oppositely disposed about the tow;
shaping the de-registered tow; and
distributing a particulate onto the shaped tow.
2. The method of claim 1 wherein said metal faced rollers being smooth, grooved, threaded, textured, or combinations thereof.
3. The method of claim 1 wherein said elastic-polymer faced roller being smooth.
4. The method of claim 1 wherein said pair of rollers being vertically aligned, one over the other.
5. The method of claim 1 wherein one said pair of rollers (S f ) rotates faster than the other pair of rollers (S a ).
6. The method of claim 5 wherein a speed ratio (S f /S a ) being in the range of 1≦S f /S a ≦2.
7. The method of claim 6 wherein the speed ratio (S f /S a ) being in the range of 1.1≦S f /S a ≦1.7.
8. The method of claim 1 further comprising shaping the de-registered tow to a substantially rectangular cross-section.
9. The method of claim 1 further comprising applying a liquid to the tow.
10. An apparatus for making an absorbent composite from a continuous tow comprising:
means for spreading a crimped tow;
means for de-registering the crimped tow by using at least two pairs of rollers, each pair of rollers having a metal faced roller and a elastic-polymer faced roller and the metal faced rollers being oppositely disposed about the tow;
means for shaping the de-registered tow; and
means for distributing a particulate onto the shaped tow.
11. The apparatus of claim 10 wherein said metal faced rollers being smooth, grooved, threaded, textured, or combinations thereof.
12. The apparatus of claim 10 wherein said elastic-polymer faced roller being smooth.
13. The apparatus of claim 10 wherein said pair of rollers being vertically aligned, one over the other.
14. The apparatus of claim 10 wherein one said pair of rollers (S f ) rotates faster than the other pair of rollers (S a ).
15. The apparatus of claim 14 a speed ratio (S f /S a ) being in the range of 1≦S f /S a ≦2.
16. The apparatus of claim 15 wherein the speed ratio (S f /S a ) being in the range of 1.1≦S f /S a ≦1.7.
17. The apparatus of claim 10 further comprising means for shaping the de-registered tow to a substantially rectangular cross-section.
18. The apparatus of claim 10 further comprising means for applying a liquid to the tow.
19. A method for making an absorbent composite from a continuous tow comprising the steps of:
spreading a crimped tow;
de-registering the crimped tow by using at least two pairs of rollers, each pair of rollers having a metal-faced roller and a elastic-polymer-faced roller, the metal faced rollers being oppositely disposed about the tow, and said pairs of rollers being vertically aligned, one said pair over the next said pair or at any angle between vertically aligned and horizontally aligned, but not including horizontally aligned;
shaping the de-registered tow; and
distributing a particulate onto the shaped tow.
20. The method of claim 19 wherein said metal faced rollers being smooth, grooved, threaded, textured, or combinations thereof.
21. The method of claim 19 wherein said elastic-polymer faced roller being smooth.
22. The method of claim 19 wherein one said pair of rollers (S f ) rotates faster than the other pair of rollers (S a ).
23. The method of claim 22 wherein a speed ratio (S f /S a ) being in the range of 1≦S f /S a ≦2.
24. The method of claim 23 wherein the speed ratio (S f /S a ) being in the range of 1.1≦S f /S a ≦1.7.
25. The method of claim 19 further comprising shaping the de-registered tow to a substantially rectangular cross-section.
26. The method of claim 19 further comprising applying a liquid to the tow.
27. An apparatus for making an absorbent composite from a continuous tow comprising:
means for spreading a crimped tow;
means for de-registering the crimped tow by using at least two pairs of rollers, each pair of rollers having a metal faced roller and a elastic-polymer faced roller, the metal faced rollers being oppositely disposed about the tow, and said pairs of rollers being vertically aligned, one said pair over the next said pair or at any angle between vertically aligned and horizontally aligned, but not including horizontally aligned;
means for shaping the de-registered tow; and
means for distributing a particulate onto the shaped tow.
28. The apparatus of claim 27 wherein said metal faced rollers being smooth, grooved, threaded, textured, or combinations thereof.
29. The apparatus of claim 27 wherein said elastic-polymer faced roller being smooth.
30. The apparatus of claim 27 wherein one said pair of rollers (S f ) rotates faster than the other pair of rollers (S a ).
31. The apparatus of claim 30 wherein a speed ratio (S f /S a ) being in the range of 1≦S f /S a ≦2.
32. The apparatus of claim 31 wherein the speed ratio (S f /S a ) being in the range of 1.1≦S f /S a ≦1.7.
33. The apparatus of claim 27 further comprising means for shaping the de-registered tow to a substantially rectangular cross-section.
34. The apparatus of claim 27 further comprising means for applying a liquid to the tow.